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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Constitutive Modeling of the Facesheet to Core Interface in Honeycomb Sandwich Panels Subject to Mode I Delamination

A new cohesive zone traction-separation law, which includes the effects of fiber bridging, has been developed, implemented with a finite element (FE) model, and applied to simulate the delamination between the facesheet and core of a composite honeycomb sandwich panel. The proposed traction-separation law includes a standard initial cohesive component, which accounts for the initial interfacial stiffness and energy release rate, along with a new component to account for the fiber bridging contribution to the delamination process. Single cantilever beam tests on aluminum honeycomb sandwich panels with carbon fiber reinforced polymer facesheets were used to characterize and evaluate the new formulation and its finite element implementation. These tests, designed to evaluate the mode I toughness of the facesheet to core interface, exhibited significant fiber bridging and large crack process zones, giving rise to a concave downward concave upward pre-peak shape in the load-displacement curve. Unlike standard cohesive formulations, the proposed formulation captures this observed shape, and its results have been shown to be in excellent quantitative agreement with experimental load-displacement and apparent critical energy release rate results, representative of a payload fairing structure, as well as local strain fields measured with digital image correlation.

composites↗
DOE OSTI2024

Electro-Chemo-Mechanical Evolution at the Garnet Solid Electrolyte–Cathode Interface

Solid-state batteries promise higher energy density and improved safety compared with lithium-ion batteries. However, electro-chemomechanical instabilities at the solid electrolyte interface with the cathode and the anode hinder their large scale implementation. Here, in this study, we focus on resolving electro-chemo-mechanical instability mechanisms and their onset conditions between a state-of-the-art cathode, LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC622), and the garnet Li 7 La 3 Zr 2 O 12 (LLZO) solid electrolyte. We used thin-film NMC622 on LLZO pellets to place the interfacial region within the detection depth of the X-ray characterization techniques. The experimental probes of the near-interface region included in operando X-ray absorption spectroscopy and ex situ focused ion beam scanning electron microscopy. Electrochemical degradation was not observable during cycling at room temperature with 4.3 V versus Li/Li + charge voltage cutoff, or with stepwise potentiostatic hold up to 4.1 V versus Li/Li + . In contrast, secondary phases including reduced transition metal species (Ni 2+ , Co 2+ ) were found after cycling up to 4.3 V versus Li/Li + at 80 °C and during potentiostatic hold at 4.3 V versus Li/Li + (Ni 2+ ). Intergranular cracks between NMC622 grains and delamination at the NMC622|LLZO interface occurred readily after the first charge. These interface reaction products and mechanical failure lowered the capacity and cell efficiency due to partial loss of the NMC622 phase, partial loss of contact at the interface, and a higher polarization resistance. Electrochemical instability between delithiated NMC622 and LLZO could be mitigated by using a low charge voltage cutoff or cycling at lower temperature. Ways to engineer the mechanical properties to avoid crack deflection and delamination at the interface are also discussed for enhancing mechanical stability.

36 MATERIALS SCIENCE↗
NASA NTRS2014

Investigating Delamination Migration in Composite Tape Laminates

A modification to a recently developed test specimen designed to investigate migration of a delamination between neighboring ply interfaces in tape laminates is presented. The specimen is a cross-ply laminated beam consisting of 40 plies with a polytetrafluoroethylene insert spanning part way along its length. The insert is located between a lower 0-degree ply (specimen length direction) and a stack of four 90-degree plies (specimen width direction). The modification involved a stacking sequence that promotes stable delamination growth prior to migration, and included a relocation of the insert from the specimen midplane to the interface between plies 14 and 15. Specimens were clamped at both ends onto a rigid baseplate and loaded on their upper surface via a piano hinge assembly, resulting in a predominantly flexural loading condition. Tests were conducted with the load-application point positioned at various locations along a specimen's span. This position affected the sequence of damage events during a test.

Ratcliffe, James G.↗
NASA NTRS2017

Simulating Matrix Crack and Delamination Interaction in a Clamped Tapered Beam

Blind predictions were conducted to validate a discrete crack methodology based on the Floating Node Method to simulate matrix-crack/delamination interaction. The main novel aspects of the approach are: (1) the implementation of the floating node method via an 'extended interface element' to represent delaminations, matrix-cracks and their interaction, (2) application of directional cohesive elements to infer overall delamination direction, and (3) use of delamination direction and stress state at the delamination front to determine migration onset. Overall, good agreement was obtained between simulations and experiments. However, the validation exercise revealed the strong dependence of the simulation of matrix-crack/delamination interaction on the strength data (in this case transverse interlaminar strength, YT) used within the cohesive zone approach applied in this work. This strength value, YT, is itself dependent on the test geometry from which the strength measurement is taken. Thus, choosing an appropriate strength value becomes an ad-hoc step. As a consequence, further work is needed to adequately characterize and assess the accuracy and adequacy of cohesive zone approaches to model small crack growth and crack onset. Additionally, often when simulating damage progression with cohesive zone elements, the strength is lowered while keeping the fracture toughness constant to enable the use of coarser meshes. Results from the present study suggest that this approach is not recommended for any problem involving crack initiation, small crack growth or multiple crack interaction.

De Carvalho, N. V.↗
NASA NTRS2003

Analysis of Plasma-Sprayed Thermal Barrier Coatings With Homogeneous and Heterogeneous Bond Coats Under Spatially Uniform Cyclic Thermal Loading

This report summarizes the results of a numerical investigation into the spallation mechanism in plasma-sprayed thermal barrier coatings observed under spatially-uniform cyclic thermal loading. The analysis focuses on the evolution of local stress and inelastic strain fields in the vicinity of the rough top/bond coat interface during thermal cycling, and how these fields are influenced by the presence of an oxide film and spatially uniform and graded distributions of alumina particles in the metallic bond coat aimed at reducing the top/bond coat thermal expansion mismatch. The impact of these factors on the potential growth of a local horizontal delamination at the rough interface's crest is included. The analysis is conducted using the Higher-Order Theory for Functionally Graded Materials with creep/relaxation constituent modeling capabilities. For two-phase bond coat microstructures, both the actual and homogenized properties are employed in the analysis. The results reveal the important contributions of both the normal and shear stress components to the delamination growth potential in the presence of an oxide film, and suggest mixed-mode crack propagation. The use of bond coats with uniform or graded microstructures is shown to increase the potential for delamination growth by increasing the magnitude of the crack-tip shear stress component.

Arnold, Steven M.↗
NASA NTRS2002

Intralaminar and Interlaminar Progressive Failure Analysis of Composite Panels with Circular Cutouts

A progressive failure methodology is developed and demonstrated to simulate the initiation and material degradation of a laminated panel due to intralaminar and interlaminar failures. Initiation of intralaminar failure can be by a matrix-cracking mode, a fiber-matrix shear mode, and a fiber failure mode. Subsequent material degradation is modeled using damage parameters for each mode to selectively reduce lamina material properties. The interlaminar failure mechanism such as delamination is simulated by positioning interface elements between adjacent sublaminates. A nonlinear constitutive law is postulated for the interface element that accounts for a multi-axial stress criteria to detect the initiation of delamination, a mixed-mode fracture criteria for delamination progression, and a damage parameter to prevent restoration of a previous cohesive state. The methodology is validated using experimental data available in the literature on the response and failure of quasi-isotropic panels with centrally located circular cutouts loaded into the postbuckling regime. Very good agreement between the progressive failure analyses and the experimental results is achieved if the failure analyses includes the interaction of intralaminar and interlaminar failures.

Goyal, Vinay K.↗
NASA NTRS1980

Stress intensity factors in two bonded elastic layers containing cracks perpendicular to and on the interface. Part 1: Analysis

The basic crack problem which is essential for the study of subcritical crack propagation and fracture of layered structural materials is considered. Because of the apparent analytical difficulties, the problem is idealized as one of plane strain or plane stress. An additional simplifying assumption is made by restricting the formulation of the problem to crack geometries and loading conditions which have a plane of symmetry perpendicular to the interface. The general problem is formulated in terms of a coupled system of four integral equations. For each relevant crack configuration of practical interest, the singular behavior of the solution near and at the ends and points of intersection of the cracks is investigated and the related characteristic equations are obtained. The edge crack terminating at and crossing the interface, the T-shaped crack consisting of a broken layer and a delamination crack, the cross-shaped crack which consists of a delamination crack intersecting a crack which is perpendicular to the interface, and a delamination crack initiating from a stress-free boundary of the bonded layers are some of the practical crack geometries considered.

Lu, M. C.↗
NASA NTRS1983

Stress intensity factors in two bonded elastic layers containing cracks perpendicular to and on the interface. I Analysis. II - Solution and results

The basic crack problem which is essential for the study of subcritical crack propagation and fracture of layered structural materials is considered. Because of the apparent analytical difficulties, the problem is idealized as one of plane strain or plane stress. An additional simplifying assumption is made by restricting the formulation of the problem to crack geometries and loading conditions which have a plane of symmetry perpendicular to the interface. The general problem is formulated in terms of a coupled systems of four integral equations. For each relevant crack configuration of practical interest, the singular behavior of the solution near and at the ends and points of intersection of the cracks is investigated and the related characteristic equations are obtained. The edge crack terminating at and crossing the interface, the T-shaped crack consisting of a broken layer and a delamination crack, the cross-shaped crack which consists of a delamination crack intersecting a crack which is perpendicular to the interface, and a delamination crack initiating from a stress-free boundary of the bonded layers are some of the practical crack geometries considered. Previously announced in STAR as N80-18428 and N80-18429

Lu, M.-C.↗
DOE OSTI2025

Impact of droplet oxidation on mechanical properties of an Al-7Si-0.4Mg alloy fabricated with liquid metal jetting

Droplet-on-demand liquid metal jetting (DOD-LMJ) is a new method for additive manufacturing of bulk structural alloys. Here, we report on the microstructure, tensile, and fatigue properties of an Al-7Si-0.4Mg (A356) alloy fabricated with LMJ. Liquid metal droplets were shielded by high-purity Ar gas shroud during deposition. Atom probe tomography revealed that a few nanometers thick (Al-Mg-Si)-O oxide film formed on the droplets despite Ar gas shielding. Tensile tests on peak-aged LMJ A356 alloy showed that yield strength was isotropic (250 MPa), but ductility was lower in the build direction (6.1 ± 1.4 %) compared to the transverse direction (9.4 ± 1.0 %). Lower ductility in the build direction was attributed to delamination of metal-oxide interfaces at layer boundaries. The ductility and yield strength of LMJ A356 were similar to cast A356 and laser powder bed fused (LPBF) A357 alloys, indicating the limited impact of oxide film on tensile properties. The oxide film severely impacted the fatigue properties. Fatigue resistance of LMJ A356 was limited by fatigue crack initiation at lack-of-fusion defects and fatigue crack propagation along layer boundaries by delamination of the metal-oxide interface. The fatigue strength of LMJ A356 at 60 MPa was lower than cast A356 and LPBF A357 alloys in the peak-aged condition. This research underscores the need for managing droplet oxidation during LMJ additive manufacturing of structural alloys.

42 ENGINEERING↗
DOE OSTI2023

Environmental barrier coatings on enhanced roughness SiC: Effect of plasma spraying conditions on properties and performance

Environmental barrier coatings for SiC/SiC composites are limited by the melting temperature of the Si bond coating near 1414°C. Systems without a bond coating may be required for future turbine applications where material temperatures go beyond 1350 °C. Here, enhanced roughness SiC substrates were developed to assess coating adhesion without the bond coating. Two EBCs with different YbMS/YbDS ratios were produced via modified plasma spraying parameters. Coating microstructure, thermal expansion, and modulus were measured for comparison of coating properties. Cyclic steam exposures at 1350°C were performed to assess oxidation resistance. The EBC with increased concentration of Yb 2 SiO 5 secondary phase displayed a higher CTE, which is typically expected to decrease adhesion lifetimes due to an increase in stress upon thermal cycling. Yet, the EBC chemistry with increased Yb 2 SiO 5 concentration was able to experience longer cycling times prior to coating delamination, likely due to interface interactions with the substrate and the thermally grown oxide.

36 MATERIALS SCIENCE↗
DOE OSTI2020

In situ characterization of foreign object damage (FOD) in environmental-barrier-coated silicon carbide (SiC) ceramic

Environmental barrier coatings (EBCs) protect advanced ceramics and ceramic matrix composites (CMCs) from oxidation and corrosion in gas turbine engine environments. Foreign object damage (FOD), where debris impact the protective coatings, is a critical hazard which limits the turbine durability. Despite previous efforts to understand FOD in EBCs, a detailed understanding of the fundamental transient damage mechanisms is still lacking. In the current work, the real-time FOD behavior of a Mullite / Silicon EBC was visualized via a dynamic synchrotron X-ray source in phase contrast imaging (PCI) configuration. Prior to the in situ FOD experiments, the microstructure and composition of the coating were respectively characterized using a scanning electron microscope (SEM) and X-ray diffraction (XRD). The variation in the properties of the debris was modeled by ~ 1.5 mm diameter Partially Stabilized Zirconia (PSZ) and Silicon Nitride (Si 3 N 4 ) spheres. A modified light-gas gun setup, synchronized with the X-ray beam, was used to propel the projectiles at velocities ranging between 300 and 355 m·s -1 . Coated samples were impacted under a fully backed support configuration and at normal incidence. Coating penetration and delamination, as well as projectile deformation at the bond coat resulted for FOD by PSZ spheres. Comparatively, projectile fracture, with subsequent rebound of fragments, as well as complete coating penetration and delamination at the substrate interface occurred for FOD by Si 3 N 4 spheres. It should be noted that only cone cracking was observed for FOD by PSZ spheres while back surface cracking was present for both projectile types. Qualitative understanding of the driving forces for the observed damage mechanisms were provided.

36 MATERIALS SCIENCE↗
DOE OSTI2023

The combined effect of temperature and seawater on the compression properties of carbon fiber vinyl ester composites for sandwich structures

For naval applications, composite sandwich structures are of significant interest, and are often manufactured using thin (2 to 4 mm) composite facings made from carbon or glass fiber reinforcement, attached to a thick (25 to 50 mm) section of PVC cellular foam or balsa wood-based core materials using a suitable polymeric resin. In the present study, we focus on the hygrothermal effect on the fiber-dominated compression properties of carbon fiber reinforced vinyl ester resin based polymeric composite (CF/VE), used as “skin” for a polymeric composite sandwich material. Hygrothermal conditioning is achieved by saturating samples in simulated seawater at 40°C. Compression properties are evaluated for coupons extracted along warp and fill undergoing- no conditioning, conditioning till saturation (up to 6 months), and long-term conditioning (2 years). Sea-water saturation yields in up to 12% drop in compression strength with a further 3–4% drop resulting from long-term conditioning. No statistically significant modulus degradation is noticed due to short or long-term hygrothermal exposure. The failure mechanism of the warp extracted coupon, which fails in a splitting failure mode originating due to the delamination between the 0/90 interface, or the fill extracted coupon, which fails due to the instability caused by tow micro-buckling, remains unchanged due to combined exposure (short or long-term) of seawater and temperature. The loss in strength is attributed to the degradation of the fiber-matrix interface, which is validated via conducting single fiber push-in tests with a nominal diameter of 7 micron for conditioned and unconditioned coupons.

Engineering↗
NASA NTRS1979

Crack barriers improve the mechanical and thermal properties of non-metallic sinter materials

Means of improving the tensile strength of ceramic composites by introducing ductile intermediate layers capable of absorbing the elastic energy at the rupture front are studied. Tests with an Al203 laminate with niobium inclusions showed that crack propagation could be successfully precluded by dissipation of the energy by deformation and/or delamination at the inclusion/matrix interface.

Gruenthaler, K. H.↗
NASA NTRS1990

An experimental investigation of delamination buckling and growth

An experimental investigation of delamination buckling and growth in compression loaded composite laminates is described. Compression tests were conducted on impact damaged laminates and laminates containing preimplanted delaminations. These tests were performed utilizing a fixture designed to prevent global buckling. The results of this study indicate that considerations in addition to initial defect geometry influence the shape of the boundary of the buckled region. Further, idealized delamination buckling from preimplanted delaminations may occur quite differently than in the case of an impact damaged laminate. The growth of a delamination following buckling may follow an irregular path and may involve the delamination growing into different interfaces.

Davidson, Barry D.↗
NASA NTRSDate not supplied

Progressive Damage Failure Analysis of a Multi-Stringer Post-Buckled Panel

Validation of a progressive damage finite element analysis model using the CompDam material model was performed on a large multi-stringer panel subjected to compressive loading. The panel had a Teflon insert embedded between the skin panel and stiffener to cause an ultimate failure mode of stiffener separation. The compressive loading of the panel caused the skin between the stiffeners to locally buckle before any damage began to occur. The post-buckled behavior of the panel was the driving mechanism to the onset of damage and the damage growth that led to skin-stiffener separation. An integrated global-local modeling approach was used to validate several aspects the overall behavior of the panel from start to failure. The global region captured the pre-buckled stiffness of the test panel within 10% and the buckling load of the skin panel at the critical location within 2%. The skin’s five half-wave buckled mode shape was accurately predicted by the model. The integrated local model captured the load corresponding to the onset of damage within 5% of the average test data. Comparisons are made for key aspects of the damage morphology, such as a growth pattern that included a significant matrix split in the first ply of the skin and a migration of the delamination from the skin-stiffener interface to the skin’sply1-ply2 interface. The ultimate failure mode was shown to be an unstable growth of delamination damage under the stiffeners which led to a peak load of the analysis that was approximately 5% above the average peak load of the testing. The validated global-local modeling approach used on the multi-stringer post-buckled panel with a Teflon insert used a methodology and lessons learned using smaller specimens applied to a subcomponent that captured several aspects of a modern aircraft design.

Jason Action↗
NASA NTRS1986

Analysis of Delamination Growth from Matrix Cracks in Laminates Subjected to Bending Loads

A major source of delamination damage in laminated composite materials is from low-velocity impact. In thin composite laminates under point loads, matrix cracks develop first in the plies, and delaminations then grow from these cracks at the ply interfaces. The purpose of this study was to quantify the combined effects of bending and transverse shear loads on delamination initiation from matrix cracks. Graphite-epoxy laminates with 90 deg. plies on the outside were used to provide a two-dimensional simulation of the damage due to low-velocity impact. Three plate bending problems were considered: a 4-point bending, 3-point bending, and an end-clamped center-loaded plate. Under bending, a matrix crack will form on the tension side of the laminate, through the outer 90 deg. plies and parallel to the fibers. Delaminations will then grow in the interface between the cracked 90 deg. ply and the next adjacent ply. Laminate plate theory was used to derive simple equations relating the total strain energy release rate, G, associated with the delamination growth from a 90 deg. ply crack to the applied bending load and laminate stiffness properties. Three different lay-ups were tested and results compared. Test results verified that the delamination always formed at the interface between the cracked 90 deg. ply and the next adjacent ply. Calculated values for total G sub c from the analysis showed good agreement for all configurations. The analysis was able to predict the delamination onset load for the cases considered. The result indicated that the opening mode component (Mode I) for delamination growth from a matrix crack may be much larger than the component due to interlaminar shear (Mode II).

Murri, G. B.↗
NASA NTRS1988

Analysis of delamination growth from matrix cracks in laminates subjected to bending loads

A major source of delamination damage in laminated composite materials is from low-velocity impact. In thin composite laminates under point loads, matrix cracks develop first in the plies, and delaminations then grow from these cracks at the ply interfaces. The purpose of this study was to quantify the combined effects of bending and transverse shear loads on delamination initiation from matrix cracks. Graphite-epoxy laminates with 90 deg plies on the outside were used to provide a two-dimensional simulation of the damage due to low-velocity impact. Three plate bending problems were considered: a 4-point bending, 3-point bending, and an end-clamped center-loaded plate. Under bending, a matrix crack will form on the tension side of the laminate, through the outer 90 deg plies and parallel to the fibers. Delaminations will then grow in the interface between the cracked 90 deg ply and the next adjacent ply. Laminate plate theory was used to derive simple equations relating the total strain energy release rate, G, associated with the delamination growth from a 90 deg ply crack to the applied bending load and laminate stiffness properties. Three different lay-ups were tested and results compared. Test results verified that the delamination always formed at the interface between the cracked 90 deg ply and the next adjacent ply. Calculated values for total G sub c from the analysis showed good agreement for all configurations. The analysis was able to predict the delamination onset load for the cases considered. The result indicated that the opening mode component (Mode I) for delamination growth from a matrix crack may be much larger than the component due to interlaminar shear (Mode II).

Murri, Gretchen Bostaph↗
NASA NTRS1991

Local delamination in laminates with angle ply matrix cracks. Part 2: Delamination fracture analysis and fatigue characterization

Constant amplitude tension-tension fatigue tests were conducted on AS4/3501-6 graphite/epoxy (02/ theta sub 2/ -(theta sub 2))sub s laminates, where theta was 15, 20, 25, or 30 degrees. Fatigue tests were conducted at a frequency of 5 Hz and an R-ratio of 0.1. Dye penetrant enhanced x-radiography was used to document the onset of matrix cracking in the central -(theta) degree plies, and the subsequent onset of local delaminations in the theta/ -(theta) interface at the intersection of the matrix cracks and the free edge, as a function of the number of fatigue cycles. Two strain energy release rate solutions for local delamination from matrix cracks were derived: one for a local delamination growing from an angle ply matrix crack with a uniform delamination growing from an angle ply matrix crack with a triangular shaped delamination area that extended only partially into the laminate width from the free edge. Plots of G(max) vs. N were generated to assess the accuracy of these G solutions. The influence of residual thermal and moisture stresses on G were also quantified. However, a detailed analysis of the G components and a mixed-mode fatigue failure criterion for this material may be needed to predict the fatigue behavior of these laminates.

Obrien, T. Kevin↗